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Old Door Bench


How to Build a Bench Using an Old Door

Do you remember the Old Door bookcase? I loved that project and was happy to see her go to a new home. But her absence left me wanting to build something else with a door. This project initially started out as a coffee table but I decided the finished project was too high. These plans can be easily adapted to a coffee table just by changing the height. I used solid oak legs that had a previous life on a bed (by “solid oak”, I mean HEAVY!!) and a narrow door, all purchased at my local Habitat for Humanity Re-Store! Regular posts can be substituted for the legs with no additional alteration! The aprons are constructed from oak PureBond plywood. Follow along as I share how to build a bench using an old door.

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I started by sanding the legs using 100 grit, 150 grit, then 220 grit. I got a stellar deal on these legs and paid $20 for all four!

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I ripped strips of plywood at 4-1/2″ wide and cut them to length. I wanted the top to overhang the ends by 4″ and the sides by 1″. I also cut a piece to use as a support in the center of the frame. I drilled pocket holes in each end of the boards then thoroughly sanded the pieces. I secure the aprons to the legs, and the support to the two longer aprons using glue and 1-1/2″ pocket hole screws. 1-1/2″ angle brackets can also be used to attach the aprons and support to the legs.

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I stained the frame using Rust-Oleum’s Summer Oak and finished with three coats of Rust-Oleum’s Ultimate Polyurethane in Matte.

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The door was 20″ wide and 79-1/2″ long so I cut it down on the table saw to a more manageable length – 62″. This is not an easy task and you will definitely need a helper! I sanded the door using the same grits of sandpaper I used for the frame.

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I painted the door using Valspar paint in Sprinkler. I used three coats, then sealed it with Rust-Oleum’s Ultimate Polyurethane in Satin. The door was then secured to the frame using glue and 2″ pocket hole screws.

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To cover the hole in the door, I used a cast iron piece I found at Hobby Lobby. It is actually the front of a hook with a screw piece on the back that mounts to the wall. I removed the mount and secured the plate to the top of the door.

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There is something about that aqua color and the oak that makes me swoon! I love it!! I am going to put her up for sale in my new flea market booth!

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Originally posted 2013-06-06 08:00:53.

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